Refractory articles and methods for forming same

ABSTRACT

A refractory article includes a body having a first portion defining at least a portion of a first exterior surface of the body, the first portion including a carbide, and further including a second portion defining at least a portion of a second exterior surface of the body opposite the first exterior surface, the second portion including an oxide, and a thermal conductivity difference (ΔTC) of at least 10 W/mK between the first exterior surface and the second exterior surface, and an average Shell Temperature of not greater than 400° C.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation application of and claims priorityunder 35 U.S.C. § 120 to U.S. patent application Ser. No. 16/683,152,entitled “REFRACTORY ARTICLES AND METHODS FOR FORMING SAME,” by JulioCesar T. SPADACCIA, et al., filed Nov. 13, 2019, which claims priorityunder 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/760,566entitled “REFRACTORY ARTICLES AND METHODS FOR FORMING SAME,” by JulioCesar T. SPADACCIA, et al., filed Nov. 13, 2018, all of which areassigned to the current assignee hereof and incorporated herein byreference in their entireties.

BACKGROUND Field of the Disclosure

The present application relates in general to refractory articles andmore specifically refractory articles including a first portion andsecond portion.

Description of the Related Art

Refractory articles, such as kiln furniture and construction materials,are required to perform under harsh conditions. For instance, furnacewalls may be constructed from refractory materials, which are ideallymade to maintain a particular temperature within the furnace, and anexterior side that will be sufficiently cool to reduce or eliminatehealth and safety concerns. The construction materials are also subjectto significant mechanical stresses and may act as load bearing objects.Thus, certain refractory articles must be sufficiently strong to meetthe necessary building tolerances. The industry continues to demandimproved refractory articles.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are illustrated by way of example and are not limited in theaccompanying figures.

FIG. 1 includes a flowchart including a process for forming a refractoryarticle according to an embodiment

FIG. 2A includes a perspective view illustration of a refractory articleaccording to an embodiment.

FIG. 2B includes a cross-sectional illustration of a portion of therefractory article of FIG. 2A.

FIG. 3 includes a perspective view illustration of a refractory articleaccording to an embodiment.

FIG. 4 includes a perspective view illustration of a refractory articleaccording to an embodiment.

FIG. 5 includes an illustration of a furnace, including a refractoryarticle according to an embodiment.

FIG. 6 includes an illustration of an image of a refractory articleaccording to Example 1.

FIG. 7 includes a perspective view illustration of a refractory articleaccording to an embodiment.

Skilled artisans appreciate that elements in the figures are illustratedfor simplicity and clarity and have not necessarily been drawn to scale.For example, the dimensions of some of the elements in the figures maybe exaggerated relative to other elements to help to improveunderstanding of embodiments of the invention.

DETAILED DESCRIPTION

The following description in combination with the figures is provided toassist in understanding the teachings disclosed herein. The followingdiscussion will focus on specific implementations and embodiments of theteachings. This focus is provided to assist in describing the teachingsand should not be interpreted as a limitation on the scope orapplicability of the teachings. However, other teachings can certainlybe used in this application.

As used herein, the terms “comprises,” “comprising,” “includes,”“including,” “has,” “having” or any other variation thereof, areintended to cover a non-exclusive inclusion. For example, a method,article, or apparatus that comprises a list of features is notnecessarily limited only to those features but may include otherfeatures not expressly listed or inherent to such method, article, orapparatus. Further, unless expressly stated to the contrary, “or” refersto an inclusive-or and not to an exclusive-or. For example, a conditionA or B is satisfied by any one of the following: A is true (or present)and B is false (or not present), A is false (or not present) and B istrue (or present), and both A and B are true (or present).

Also, the use of “a” or “an” is employed to describe elements andcomponents described herein. This is done merely for convenience and togive a general sense of the scope of the invention. This descriptionshould be read to include one or at least one and the singular alsoincludes the plural, or vice versa, unless it is clear that it is meantotherwise. For example, when a single embodiment is described herein,more than one embodiment may be used in place of a single embodiment.Similarly, where more than one embodiment is described herein, a singleembodiment may be substituted for that more than one embodiment.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The materials, methods, andexamples are illustrative only and not intended to be limiting. To theextent that certain details regarding specific materials and processingacts are not described, such details may include conventionalapproaches, which may be found in reference books and other sourceswithin the manufacturing arts.

The following is directed towards refractory articles and methods offorming refractory articles. Such refractory articles may be suitablefor use in various high temperature applications, including, forexample, kiln furniture and/or construction materials.

FIG. 1 includes a flowchart illustrating a process for forming arefractory article according to an embodiment. As illustrated, theprocess can be started by placing a first material into a productiontool at step 101. As illustrated in FIG. 1, the process may be initiatedby placing the first material into a production tool at step 101. Theprocess may further include placing a second material into theproduction tool at step 103. The process may also include forming agreen body at step 105. Step 107 can include forming the refractoryarticle.

The first material can be a dry mixture or a wet mixture, wherein a wetmixture includes a least one liquid additive. For example, the firstmaterial may include one or more dry powder components combinedtogether. In still another embodiment, the first material may be a wetmixture including solid material contained in a liquid carrier, such asin the form of a slurry. In accordance with an embodiment, the firstmaterial may include a ceramic material, such as an oxide, carbide,boride, nitride, or any combination thereof. In particular instances,the first material can include a powder material, including a carbide,such as silicon carbide.

The first material may be placed into a cavity in the production tool.In certain instances, the first material can be placed into theproduction tool by depositing the first material into a cavity in theproduction tool, such that the first material forms a layer in a portionof the cavity of the production tool.

The production tool may be an object having a cavity of a desired sizeand shape to facilitate forming the desired refractory article. Forexample, the production tool may include a mold. In at least oneembodiment, the green body and finally-formed refractory article may beformed in the same production tool. In an alternative embodiment, theproduction tool may be a vessel or system for forming the green bodyand/or finally-formed refractory article. For example, the productiontool may be an additive manufacturing chamber (e.g., three-dimensionalprinting chamber), wherein the green body is formed from the controlledformation of smaller components. Accordingly, the production tool neednot necessarily be limited to mold.

After placing the first material into a production tool, the process cancontinue at step 103 by placing a second material into the productiontool. The second material can include a dry mixture or wet mixture. Thesecond material can be deposited into the same cavity containing thefirst material. More specifically, the second material can be depositedas a layer overlying the first material. For example, the secondmaterial may be overlying and in direct contact with the first material.In at least one embodiment, the process of placing the first and secondmaterials into the production tool can include selectively layering thefirst material as a first layer and depositing the second material intothe same cavity of the production tool as a layer in direct contact withand overlying the layer of the first material. It will be appreciatedthat the order of materials deposited into the cavity can be altereddepending upon the forming process.

The second material can include an oxide, carbide, boride, nitride, orany combination thereof. In one particular embodiment, the secondmaterial includes an oxide compound, such as alumina, silica, and thelike. In certain instances, the second material may include a silicate,such as an aluminosilicate compound. An example of such analuminosilicate compound can include mullite (3Al₂O₃-2SiO₂ or2Al₂O₃—SiO₂). In at least one embodiment, the second material caninclude a ceramic powder material consisting of mullite.

In certain senses, the process may include depositing a plurality ofmaterials in the production tool in a controlled manner. For example,the process may further include an optional process of placing a thirdmaterial into the production tool, wherein the third material can bedisposed between the first material and the second material. In moreparticular instances, the third material may be disposed between andabutting both the first material and the second material. Like the firstor second material, the third material may be a dry material or a wetmaterial and may have any of the attributes of those materials asdescribed herein.

For those embodiments utilizing a third material, a distinct thirdportion can be formed in the green body and the finally-formedrefractory article. The third portion can be disposed between the firstand second portions. Furthermore, it will be appreciated that anyprocesses conducted on the first material and second material areconducted on the third material. It will also be understood that thegreen body can include any number of distinct portions layered relativeto each other.

According to one particular embodiment, the third material can be amixture of the first material and second material. The relative ratio ofthe first material and second material can be altered depending upon theintended application. For example, the third material can include amixture of the first material and the second material as a mixture ratioMr=(M1/M2) of at least 0.1, wherein M1 represents the content (wt %) ofthe first material in the mixture and M2 represents the content (wt %)of the second material in the mixture. For example, the mixture ratio(Mr) can be at least 0.2, such as at least 0.3 or at least 0.4 or atleast 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least0.9 or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or atleast 1.4 or at least 1.5 or at least 1.6 or at least 1.7 or at least1.8 or at least 1.9 or at least 2 or at least 2.2 or at least 2.5 or atleast 2.7 or at least 3 or at least 3.2 or at least 3.5 or at least 4 orat least 5 or at least 6 or at least 7 or at least 8 or at least 9 or atleast 10. Still, in one non-limiting embodiment, the mixture ratio (Mr)can be not greater than 10, such as not greater than 9 or not greaterthan 8 or not greater than 7 or not greater than 6 or not greater than 5or not greater than 4 or not greater than 3 or not greater than 2.5 ornot greater than 2 or not greater than 1.8 or not greater than 1.5 ornot greater than 1.2 or not greater than 1 or not greater than 0.9 ornot greater than 0.8 or not greater than 0.7 or not greater than 0.6 ornot greater than 0.5 or not greater than 0.4 or not greater than 0.3. Itwill be appreciated that the mixture ratio (Mr) can be within a rangeincluding any of the minimum and maximum values noted above.

The first and second materials (and any number of other optionalmaterials) can be formed into the green body at step 105. The green bodycan have a first portion including the first material and a secondportion including the second material. Certain suitable processes forforming the green body can include molding, casting, pressing, drying,cooling, heating, irradiating, or any combination thereof. In oneparticular embodiment, the process of forming the green body can includepressing the combination of the first material and the second materialin the production tool to form a green body. Some suitable examples ofsuch processes can include cold pressing, warm pressing, hot pressing,or any combination thereof.

In one embodiment the process of forming the green body and therefractory article can be completed in a single forming process in asingle processing vessel (e.g., the production tool). Instead, thefinally-formed refractory article may be formed directly from the rawmaterials deposited in the production tool, such that a free-standinggreen body may not necessarily be formed and removed from the processingvessel. One example includes an additive manufacturing process thatforms the green body and fires the green body in the same processingvessel. Still, it will be understood that other processes may form afree-standing green body that is subject to one or more processes and/orhandling prior to the process used to form the finally-formed refractoryarticle.

After forming the green body at step 105, the process can continue atstep 107 by forming a refractory article from the green body. Theprocess of forming the refractory article can include firing the greenbody. In one particular embodiment, forming the refractory article caninclude firing the green body at a firing temperature of at least 1200°C., such as at least 1300° C. at least 1400° C. or even at least 1500°C. In another embodiment, the firing temperature may be not greater than2000° C., such as not greater than 1900° C. or not greater than 1800° C.or not greater than 1700° C. It will be appreciated that the firingtemperature can be within a range between any of the minimum and maximumvalues noted above, including, for example, within range of at least1200° C. to not greater than 2000° C.

The firing process may be conducted in a particular atmosphere. Forexample, the firing atmosphere may include at least one atmosphericcondition from the group of inert, oxidizing, reducing, ornitrogen-rich. In one particular embodiment, the atmospheric conditionduring firing can be a nitrogen-rich atmosphere, such that at least themajority (i.e., at least 51 vol %) or at least 60 vol % or at least 80vol % or even at least 99 vol % of the atmosphere is nitrogen. In aparticular embodiment, the atmosphere during firing may include acombination of conditions, including, for example, a first portion ofthe firing process conducted in a nitrogen-rich atmosphere, andthereafter, a second portion of the firing process can be conducted inan inert or oxidizing atmosphere.

In accordance with an embodiment, the process of forming the refractoryarticle can include co-firing the first portion and second portion ofthe green body associated with the first material and second material,respectively. In a co-firing process, the first portion and secondportion may be bonded to each other through necking and grain growthmechanisms. Still, as described in other embodiments, one or moreportions (e.g., a third portion) may be disposed between the first andsecond portions to facilitate improved formation and performance of therefractory article.

As illustrated in FIG. 2A, the refractory article 200 can have a body201. The body 201 of FIG. 2A is illustrated as having a cubiclethree-dimensional shape; however, it will be appreciated that othersizes and shapes that the refractory article may be suitable dependingupon the intended application. The body 201 can include surfaces 203,204, 205, 206, 207, and 208 (203-208) that define the exterior surfaceof the body 201. As further illustrated, the body 201 may include afirst portion 210, a second portion 211, and (optionally) a thirdportion 212, where the third portion 212 may be disposed between thefirst portion 210 and the second portion 211. In one embodiment, thefirst portion 210 can include at least a portion of the exterior surfaceof the body 201, including, for example, the entirety of surface 204 andportions of the surfaces 203, 205, 206, 208. In another embodiment, thesecond portion 211 can include at least a portion of the exteriorsurface of the body 201, including, for example, the surface 207 andportions of the surfaces 203, 205, 206, 208. Notably, the surface 204,which is defined entirely by the first portion 210 can be opposite thesurface 207, which is defined entirely by the second portion 211. Suchan arrangement may be advantageous for providing the desired thermalcharacteristics at opposite sides of the body 201. In certain instances,the exterior surface 204 may be referred to as the first exteriorsurface of the body 201, and the exterior surface 207 may be referred toas the second exterior surface of the body.

As further illustrated, the body 201 can include a length (l), athickness (t), and a height (h). The thickness typically extends in adirection transverse to the portions, such that the smallest dimensionof the portions 210, 211, and 212 can be defined by their thickness, asprovided in FIG. 2B. Reference to the length (l), the height (h), or thethickness (t) of the body 201 will be understood to reference theaverage length (l), average height (h), or average thickness (t) of thebody 201. Generally, the length is greater than or equal to the height,and the height is greater than or equal to the thickness.

The first portion 210 can have a first average thickness (T₁). Thesecond portion 211 may include a second average thickness (T₂). Andfurthermore, the third portion 212 may have a third average thickness(T₃). The average thickness of each portion can be evaluated from asuitable cross-section of the body such that a suitable number ofrandomly selected measurements can be made and averaged. The embodimentof FIG. 2B demonstrates that the body is created such that the portions210, 211, and 212 vary in the direction of the thickness of the body201. It will be understood that alternative bodies can be formed suchthat the portions vary in the direction of the length or width of thebody. For example, referring briefly to FIG. 4, the body 401 has avarying portion extending in the direction of the length 480. Thedimensions of width 481 and thickness 482 do not define directions thatextend through all of the portions 410, 411, and 412 of the body 401.

In accordance with an embodiment, at least a portion of the exteriorsurfaces of the body 201 may be defined by the first portion 210. Forexample, the first portion 210 may define not greater than 90% of thetotal exterior surface area of the body 201, such as not greater than80% or not greater than 70% or not greater than 60% or not greater than50% or not greater than 40% or not greater than 30% or not greater than20% or not greater than 10%. Still, in one non-limiting embodiment, thefirst portion 210 can define and account for at least 1% of the totalexterior surface area of the body 201, such as at least 5% or at least10% or at least 20% or at least 30% or at least 40% or at least 50% orat least 60% or at least 70% or at least 80%. It will be appreciatedthat the first portion 210 can define a percentage of the total exteriorsurface area of the body 201 within a range, including any of theminimum and maximum percentages noted above.

Furthermore, at least a portion of the first exterior surface 204 may bedefined by the first portion 210. For example, at least 50% of the firstexterior surface 204 may be defined by the first portion 210, such as atleast 60% or at least 70% or at least 80% or at least 90% or at least99%. In one particular embodiment, essentially all of the first exteriorsurface 204 can be defined by the first portion 210. The first exteriorsurface 204 may be associated with the hot surface of the refractoryarticle, which may be closest to a high temperature environment (e.g.,the interior wall of a furnace). In one particular embodiment, the firstportion may be spaced apart entirely from the second exterior surface207 of the body 201, such that the second exterior surface may be freeof the first portion and first material.

In accordance with an embodiment, the first portion 210 can include acarbide. For example, the first portion 210 may include silicon carbide.In another embodiment, the first portion 210 may include at least onematerial from the group of oxygen, nitrogen, compounds (e.g., oxides ornitrides), or any combination thereof. In more particular instances, thefirst portion 210 may include a multi-phase material, including aprimary phase including silicon carbide, and a secondary phasecomprising oxygen, nitrogen, compounds thereof, or any combinationthereof. The primary phase may be present in a greater content (vol %)compared to the secondary phase. In a particular embodiment, the firstportion 210 can comprise nitride-bonded silicon carbide, and morespecifically, may consist essentially of nitride-bonded silicon carbide.In another embodiment, the first portion 210 may include anoxynitride-bonded silicon carbide, and more particularly, the firstportion 210 may consist essentially of oxynitride-bonded siliconcarbide. In yet another embodiment, the first portion 210 may consistessentially of silicon carbide.

In accordance with an embodiment, the first portion 210 can include acertain content of polycrystalline oxide material that may facilitateimproved performance of the refractory article. For example, the firstportion 210 may include a majority content (at least 51 vol %) ofpolycrystalline material. For example, the first portion 210 can includeat least 60 vol % of polycrystalline material for a total volume of thefirst portion 210 or at least 70 vol % or at least 80 vol % or at least90 vol % or at least 95 vol % of a polycrystalline material for a totalvolume of the first portion 210. In one embodiment, the first portion210 can consist essentially of a polycrystalline material. Still, in atleast one non-limiting embodiment, the first portion 210 can include notgreater than 99 vol % percent polycrystalline material, such as notgreater than 95 vol % or not greater than 90 vol % or not greater than85 vol %. It will be appreciated that the first portion 210 can have acontent of polycrystalline material within a range, including any of theminimum and maximum percentages noted above.

For those embodiment having a first portion 210 including a multi-phasematerial including at least a primary phase and a secondary phase, suchmaterial may have a particular content of the primary phase to thesecondary phase that may facilitate improved performance of therefractory article. For example, the first portion 210 may have acontent ratio, Cr1=(SC2/PC1), of at least 0.1, wherein PC1 is thecontent (vol %) of the primary phase, and SC2 is the content (vol %) ofthe secondary phase. In other instances, the content ratio of the firstportion (Cr1) can be at least 0.001 or at least 0.01 or at least 0.1 orat least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1 or atleast 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least 1.9 orat least 2 or at least 2.2 or at least 2.5 or at least 2.7 or at least 3or at least 3.2 or at least 3.5 or at least 4 or at least 5 or at least6 or at least 7 or at least 8 or at least 9 or at least 10. In anothernon-limiting embodiment, the first portion 210 may have a content ratioof not greater than 1000, such as not greater than 100 or not greaterthan 10 or not greater than 9 or not greater than 8 or not greater than7 or not greater than 6 or not greater than 5 or not greater than 4 ornot greater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0. It will be appreciated that thecontent ratio (Cr) can be within a range including any of the minimumand maximum values noted above.

In accordance with another embodiment, the first portion 210 can have aparticular average thermal conductivity that may facilitate improvedperformance of the refractory article. For example, the first portion 20can have an average thermal conductivity of at least 10 W/mK at 1200°C., such as at least 11 W/mK or at least 12 W/mK or at least 13 W/mK orat least 14 W/mK or at least 15 W/mK or at least 16 W/mK or at least 17W/mK or at least 18 W/mK. In still another embodiment, the first portion210 can have an average thermal conductivity of not greater than 30 W/mKor not greater than 28 W/mK or not greater than 26 W/mK or not greaterthan 24 W/mK or not greater than 22 W/mK or not greater than 20 W/mK ornot greater than 18 W/mK or not greater than 16 W/mK. It will beappreciated that the first portion 210 can have an average thermalconductivity within a range including any of the minimum and maximumvalues noted above, including, for example, within a range of at least10 W/mK and not greater than 30 W/mK. The average thermal conductivityis measured according to ASTM E1461 (Thermal Diffusivity by the FlashMethod).

In still another embodiment, the first portion 210 can include amaterial having a particular average crystallite size that mayfacilitate improved performance. For example, the first portion 210 mayhave a primary phase including polycrystalline material having anaverage crystallite size of at least 1 micron, such as at least 10microns or at least 25 microns or at least 50 microns or at least 100microns or at least 250 microns or at least 500 microns or at least 1 mmor at least 2 mm or at least 3 mm or at least 4 mm or at least 5 mm orat least 6 mm or at least 7 mm or at least 8 mm or at least 9 mm. Inanother non-limiting embodiment, the first portion 210 may have aprimary phase including a polycrystalline material (e.g., siliconcarbide) having an average crystallite size of not greater than 10 mm,such as not greater than 9 mm or not greater than 8 mm or not greaterthan 7 mm or not greater than 6 mm or not greater than 5 mm or notgreater than 4 mm or not greater than 3 mm or not greater than 2 mm ornot greater than 1 mm or not greater than 800 microns or not greaterthan 500 microns or not greater than 200 microns or not greater than 100microns or not greater than 50 microns. It will be appreciated that thefirst portion 210 may include a primary phase comprising silicon carbidehaving average crystallite size within a range including any of theminimum and maximum values noted above, such as within a range of atleast 1 micron to not greater than 10 mm. The average crystallite sizecan be measured according to the uncorrected intercept method.

Reference herein to average crystallite size may also be referred to asaverage domain size or average grain size, wherein the domain,crystallite, or grain refers to a monocrystalline region defined by agrain boundary and typically abutting or connecting another adjacentcrystallite, grain, or domain.

The first portion 210 can have an average thickness that may facilitateimproved performance of the refractory article. For example, the firstportion 210 can have an average thickness (T₁) of at least 10% of thetotal thickness (t) of the body 201, such as at least 20% or at least30% or at least 40% or at least 50% or at least 60% or at least 70% orat least 80% of a total thickness (t) of the body 201. In still anotherembodiment, the average thickness (T₁) of the first portion 210 can benot greater than 90% of a total thickness (t) of the body 201, such asnot greater than 80% or not greater than 70% or not greater than 60% ornot greater than 50% or not greater than 40% or not greater than 30% ornot greater than 20% of a total thickness (t) of the body 201. It willbe appreciated that the average thickness (T₁) of the first portion 210can be within a range including any of the minimum and maximumpercentages noted above. A suitable process for evaluating the averagethickness (T₁) of the first portion 210 can include sectioning the body201 to obtain a cross-sectional portion as illustrated in FIG. 2B andmeasuring the thickness of the first portion 210 in at least threerandomly selected regions.

Furthermore, it will be understood that for those embodiments where theportions vary in the dimension of length (e.g., the embodiment of FIG.4) or the dimension of width, the same relative relationship between thedimension of the first portion to the dimension of the body can exist.For example, in certain instances, the refractory article may be formedsuch that the portions vary in the direction of the length of the body.The first portion 210 may have an average length that is at least 10% ofthe total length of the body, such as at least 20% or at least 30% or atleast 40% or at least 50% or at least 60% or at least 70% or at least80% of a total length (l) of the body. Furthermore, for suchembodiments, the average length of the first portion can be not greaterthan 90% of a total length of the body 201, such as not greater than 80%or not greater than 70% or not greater than 60% or not greater than 50%or not greater than 40% or not greater than 30% or not greater than 20%of a total length (l) of the body. It will be appreciated that theaverage length of the first portion can be within a range, including anyof the minimum and maximum percentages noted above. The same may applyfor the average length of the second and third portions relative to thetotal length of the body.

It will also be understood that in certain embodiments, the portions mayvary in the dimension of the width of the body. In such cases, theaverage width of the first portion may be at least 10% of the totalwidth of the body, such as at least 20% or at least 30% or at least 40%or at least 50% or at least 60% or at least 70% or at least 80% of atotal width (w) of the body. Furthermore, for such embodiments, theaverage width of the first portion can be not greater than 90% of atotal width of the body 201, such as not greater than 80% or not greaterthan 70% or not greater than 60% or not greater than 50% or not greaterthan 40% or not greater than 30% or not greater than 20% of a totalwidth (w) of the body. It will be appreciated that the average width ofthe first portion can be within a range, including any of the minimumand maximum percentages noted above. The same may apply for the averagewidth of the second and third portions relative to the total width (w)of the body.

In another embodiment, the average thickness (T₁) of the first portion210 can be at least 1 mm or at least 5 mm or at least 10 mm or at least25 mm or at least 50 mm or at least 100 mm or at least 200 mm or atleast 500 mm. In another embodiment, the average thickness (T1) of thefirst portion 210 can be not greater than 10 m, such as not greater than5 m or not greater than 3 m or not greater than 1 m or not greater than800 mm or not greater than 500 mm or not greater than 200 mm or notgreater than 100 mm. It will be appreciated that the average thicknessof the first portion 210 can be within a range including any of theminimum and maximum values noted above.

In accordance with another embodiment, the second portion 211 mayinclude a certain material that facilitates the improved performance ofthe refractory article. For example, the second portion 211 can includean oxide-containing compound, including, for example, alumina (Al₂O₃),silica (SiO₂), or any combination thereof. In a more particularembodiment, the second portion can include an aluminosilicate, such asmullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂). In at least one embodiment, thesecond portion 211 consists essentially of mullite (3Al₂O₃-2SiO₂ or2Al₂O₃—SiO₂).

In accordance with an embodiment, the second portion 211 can include acertain content of polycrystalline oxide material that may facilitateimproved performance of the refractory article. For example, the secondportion 211 may include a majority content (at least 51 vol %) ofpolycrystalline oxide material. For example, the second portion caninclude at least 60 vol % of a polycrystalline oxide material for atotal volume of the second portion or at least 70 vol % or at least 80vol % or at least 90 vol % or at least 95 vol % of a polycrystallineoxide material for a total volume of the second portion. In oneembodiment, the second portion can consist essentially of apolycrystalline oxide material. Still, in at least one non-limitingembodiment, the second portion 211 can include not greater than 99 vol %percent polycrystalline material, such as not greater than 95 vol % ornot greater than 90 vol % or not greater than 85 vol %. It will beappreciated that the second portion 211 can have a content ofpolycrystalline material within a range, including any of the minimumand maximum percentages noted above.

In a more particular embodiment, the second portion may include amajority content (at least 50 vol %) of polycrystalline mullite for atotal volume of the second portion 211. In other instances, thepercentage of polycrystalline mullite in the second portion 211 can begreater, such as at least 60 vol % of a polycrystalline mullite for atotal volume of the second portion or at least 70 vol % or at least 80vol % or at least 90 vol % or at least 95 vol % of a polycrystallinemullite for a total volume of the second portion. In at least oneembodiment, the second portion 211 can consist essentially ofpolycrystalline mullite. In still another embodiment, the second portion211 can be essentially free of amorphous phase material.

The second portion 211 may have a polycrystalline phase having aparticular average crystallite size (i.e., grain size) that mayfacilitate improved performance. For example, the second portion 211 mayinclude a polycrystalline material having an average crystallite size ofat least 1 micron, such as at least 10 microns or at least 25 microns orat least 50 microns or at least 100 microns or at least 250 microns orat least 500 microns or at least 1 mm or at least 2 mm or at least 3 mmor at least 4 mm or at least 5 mm or at least 6 mm or at least 7 mm orat least 8 mm or at least 9 mm. In another non-limiting embodiment, thesecond portion 211 may have a polycrystalline phase (e.g., mullite)having an average crystallite size of not greater than 10 mm, such asnot greater than 9 mm or not greater than 8 mm or not greater than 7 mmor not greater than 6 mm or not greater than 5 mm or not greater than 4mm or not greater than 3 mm or not greater than 2 mm or not greater than1 mm or not greater than 800 microns or not greater than 500 microns ornot greater than 200 microns or not greater than 100 microns or notgreater than 50 microns. It will be appreciated that the second portion211 may include a polycrystalline phase having an average crystallitesize within a range including any of the minimum and maximum valuesnoted above, such as within a range of at least 1 micron to not greaterthan 10 mm. The average crystallite size can be measured according tothe uncorrected intercept method.

In another aspect, the second portion 211 of the body 201 can define acertain percentage of the total exterior surface area of the body 201that may facilitate improved performance of the refractory article. Forexample, the second portion 211 may define not greater than 90% of thetotal exterior surface area of the body 201, such as not greater than80% or not greater than 70% or not greater than 60% or not greater than50% or not greater than 40% or not greater than 30% or not greater than20% or not greater than 15% or not greater than 10% or not greater than8% or not greater than 5% or not greater than 3%. Still, anothernon-limiting embodiment, the second portion 211 can define at least 1%of the total exterior surface area of the body 201, such as at least 2%or at least 3% or at least 5% or at least 8% or at least 10% or at least12% or at least 15% or at least 20% or at least 25% or at least 30% orat least 40% or at least 50% or at least 60%. It will be appreciatedthat the second portion 211 can define a percentage of the totalexterior surface area of the body 201 within a range, including any ofthe minimum and maximum percentages noted above.

Furthermore, at least a portion of the second exterior surface 207 maybe defined by the second portion 211. For example, at least 50% of thesecond exterior surface 207 may be defined by the second portion 211,such as at least 60% or at least 70% or at least 80% or at least 90% orat least 99%. In one particular embodiment, essentially all of thesecond exterior surface 207 can be defined by the second portion 211.The second exterior surface 207 may be associated with a cool surface ofthe refractory article, which may be furthest from a high temperatureenvironment (e.g., the exterior wall of a furnace). At least a portionof the second exterior surface 207 of the body 201 can be opposite thefirst exterior surface 204. Furthermore, the second portion 211 may bespaced apart entirely from the first exterior surface 204 of the body201, such that the first exterior surface 204 may be free of the secondportion 211 and the second material.

In accordance with another embodiment, the second portion 211 can have aparticular average thermal conductivity that may facilitate improvedperformance of the refractory article. For example, the second portion211 can have an average thermal conductivity of not greater than 10W/mK, such as not greater than 8 W/mK or not greater than 7 W/mK or notgreater than 6 W/mK or not greater than 5 W/mK or not greater than 4W/mK or not greater than 2 W/mK or not greater than 1 W/mK. In stillanother embodiment, the second portion 211 can have an average thermalconductivity of at least 0.5 W/mK or at least 1 W/mK or at least 2 W/mKor at least 3 W/mK or at least 4 W/mK or at least 5 W/mK or at least 6W/mK or at least 7 W/mK or at least 8 W/mK. It will be appreciated thatthe second portion 211 can have an average thermal conductivity within arange including any of the minimum and maximum values noted above,including, for example, within a range of at least 0.5 W/mK and notgreater than 10 W/mK. The average thermal conductivity is measuredaccording to ASTM E1461.

In at least one embodiment, the refractory article 200 can have a body201 that may have a certain thermal conductivity difference between thefirst portion 210 and the second portion 211 that may facilitateimproved performance. For example, the body 201 can have a thermalconductivity difference ΔTC=TC1−TC2 of not greater than 200 W/mK,wherein TC1 is the average thermal conductivity of the first portion 210and TC2 is the average thermal conductivity of the second portion 211.In other instances, the thermal conductivity difference ΔTC can be notgreater than 180 W/mK or not greater than 160 W/mK or not greater than140 W/mK or not greater than 120 W/mK or not greater than 100 W/mK ornot greater than 90 W/mK or not greater than 80 W/mK or not greater than70 W/mK or not greater than 60 W/mK or not greater than 50 W/mK or notgreater than 45 W/mK or not greater than 40 W/mK or not greater than 35W/mK or not greater than 30 W/mK or not greater than 25 W/mK or notgreater than 22 W/mK or not greater than 20 W/mK. In yet anotherembodiment, the thermal conductivity difference (ΔTC) can be at least 10W/mK, such as at least 13 W/mK or at least 14 W/mK or at least 15 W/mKor at least 16 W/mK or at least 17 W/mK or at least 18 W/mK or at least20 W/mK or at least 25 W/mK or at least 30 W/mK or at least 35 W/mK orat least 40 W/mK or at least 45 W/mK or at least 50 W/mK or at least 55W/mK or at least 60 W/mK or at least 70 W/mK or at least 80 W/mK or atleast 90 W/mK or at least 100 W/mK. It will be appreciated that therefractory article can have a thermal conductivity difference within arange, including any of the minimum and maximum values noted above. Thethermal conductivity difference can be measured at the surface of thefirst and second exterior surfaces 204 and 207, and thus may also beconsidered the thermal conductivity difference between the firstexterior surface 204 and the second exterior surface 207.

In yet another embodiment, the refractory article may have a particularcoefficient of thermal expansion difference between the first portion210 and the second portion 210 that may facilitate an improvement in theperformance of the refractory article. For example, the body 201 mayhave a coefficient of thermal expansion difference (ΔCTE=CTE1−CTE2) ofnot greater than 5 10⁻⁶/° C., wherein CTE1 is the average coefficient ofthermal expansion of the first portion and CTE2 is the averagecoefficient of thermal expansion of the second portion 211. In otherinstances the coefficient of thermal expansion difference (ΔCTE) can benot greater than 4.8×10⁻⁶/° C. or not greater than 4.6×10⁻⁶/° C. or notgreater than 4.4×10⁻⁶/° C. or not greater than 4.2×10⁻⁶/° C. or notgreater than 4×10⁻⁶/° C. or not greater than 3.8 s 10⁻⁶/° C. or notgreater than 3.6×10⁻⁶/° C. or not greater than 3.4×10⁻⁶/° C. or notgreater than 3.2×10⁻⁶/° C. or not greater than 3×10⁻⁶/° C. or notgreater than 2.9×10⁻⁶/° C. or not greater than 2.8×10⁻⁶/° C. or notgreater than 2.7×10⁻⁶/° C. or not greater than 2.6×10⁻⁶/° C. or notgreater than 2.5×10⁻⁶/° C. or not greater than 2.4×10⁻⁶/° C. or notgreater than 2.3×10⁻⁶/° C. or not greater than 2.2×10⁻⁶/° C. or notgreater than 2.1×10⁻⁶/° C. or not greater than 2×10⁻⁶/° C. or notgreater than 1.9×10⁻⁶/° C. or not greater than 1.8×10⁻⁶/° C. or notgreater than 1.7×10⁻⁶/° C. or not greater than 1.6×10⁻⁶/° C. or notgreater than 1.5×10⁻⁶/° C. or not greater than 1.4×10⁻⁶/° C. or notgreater than 1.3×10⁻⁶/° C. or not greater than 1.2×10⁻⁶/° C. or notgreater than 1.1×10⁻⁶/° C. or not greater than 1×10⁻⁶/° C. or notgreater than 0.9×10⁻⁶/° C. or not greater than 0.8×10⁻⁶/° C. or notgreater than 0.7×10⁻⁶/° C. or not greater than 0.6×10⁻⁶/° C. or notgreater than 0.5×10⁻⁶/° C. or not greater than 0.4×10⁻⁶/° C. or notgreater than 0.3×10⁻⁶/° C. or not greater than 0.2×10⁻⁶/° C. or notgreater than 0.1×10⁻⁶/° C. The CTE is measured according to ASTM C832(Standard Test Method of Measuring Thermal Expansion and Creep ofRefractories Under Load, which will be referred to herein as the“Coefficient of Thermal Expansion” and is a valid value up to 1500° C.).In another embodiment, coefficient of thermal expansion difference(ΔCTE) can be at least 0.001×10⁻⁶/° C. or at least 0.01×10⁻⁶/° C. or atleast 0.1×10⁻⁶/° or at least 0.5×10⁻⁶/° C. or at least 1×10⁻⁶/° C. Itwill be appreciated that the coefficient of thermal expansion differencemay be within a range including any of the minimum and maximum valuesnoted above.

The refractory article may be formed such that the second portion 211has a particular average thickness (T₂) relative to the total thickness(t) of the body 201. For example, the second portion 211 can have anaverage thickness (T₂) of at least 5% of the total thickness of the body201, such as at least 6% or at least 7% or at least 8% or at least 9% orat least 10% or at least 15% or at least 20% or at least 25% or at least30% or at least 35% or at least 40% or at least 50% or at least 55% orat least 60% of a total thickness (t) of the body 201. Still, in atleast one non-limiting embodiment, the second portion 211 can have anaverage thickness of not greater than 90% of a total thickness (t) ofthe body 201, such as not greater than 80% or not greater than 70% ornot greater than 60% or not greater than 50% or not greater than 40% ornot greater than 30% or not greater than 20% or not greater than 10% ofa total thickness (t) of the body 201. It will be appreciated that theaverage thickness of the second portion 211 relative to the totalthickness (t) of the body 201 can be within a range including any of theminimum and maximum values noted above.

As noted above with respect to the first portion 210, alternativeembodiments can have the portions varying with respect to the length orwidth of the body. In such instances, the relative average length to thetotal length of the body can have the same percentages as noted abovefor the relative average thickness of the second portion to the totalthickness of the body. For example, in embodiments where the portionsvary along the dimension of length, the relative average length of thesecond portion can be at least 5% of the total length of the body, suchas at least 6% or at least 7% or at least 8% or at least 9% or at least10% or at least 15% or at least 20% or at least 25% or at least 30% orat least 35% or at least 40% or at least 50% or at least 55% or at least60% of a total length (l) of the body. Still, in at least onenon-limiting embodiment, the second portion can have an average lengthof not greater than 90% of a total length (l) of the body, such as notgreater than 80% or not greater than 70% or not greater than 60% or notgreater than 50% or not greater than 40% or not greater than 30% or notgreater than 20% or not greater than 10% of a total length (l) of thebody. It will be appreciated that the average length of the secondportion relative to the total length (l) of the body can be within arange including any of the minimum and maximum values noted above.

In another aspect, the body can have portions that vary along thedimension of width. In such embodiments, the relative average width ofthe second portion can be at least 5% of the total width (w) of thebody, such as at least 6% or at least 7% or at least 8% or at least 9%or at least 10% or at least 15% or at least 20% or at least 25% or atleast 30% or at least 35% or at least 40% or at least 50% or at least55% or at least 60% of a total length (l) of the body. Still, the secondportion can have an average width of not greater than 90% of a totalwidth (w) of the body, such as not greater than 80% or not greater than70% or not greater than 60%, or not greater than 50% or not greater than40% or not greater than 30% or not greater than 20% or not greater than10% of a total width (w) of the body. It will be appreciated that theaverage width of the second portion relative to the total width (w) ofthe body can be within a range, including any of the minimum and maximumvalues noted above.

In at least one aspect, controlling the relative average thickness (T₁)of the first portion 210 to the average thickness (T₂) of the secondportion 211 may facilitate the formation of an improved factory article.For example, the first portion 210 may have a first average thickness(T₁) and the second portion 211 may have a second average thickness(T₂), and the body 201 can have a thickness ratio, Tr=(T₁/T₂), that isat least 0.1, such as at least 0.2 or at least 0.3 or at least 0.4 or atleast 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least0.9 or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or atleast 1.4 or at least 1.5 or at least 1.6 or at least 1.7 or at least1.8 or at least 1.9 or at least 2 or at least 2.2 or at least 2.5 or atleast 2.7 or at least 3 or at least 3.2 or at least 3.5 or at least 4 orat least 5 or at least 6 or at least 7 or at least 8 or at least 9 or atleast 10. Still, at least one non-limiting embodiment, the thicknessratio, Tr=(T₁/T₂), may be not greater than 10, such as not greater than9 or not greater than 8 or not greater than 7 or not greater than 6 ornot greater than 5 or not greater than 4 or not greater than 3 or notgreater than 2.5 or not greater than 2 or not greater than 1.8 or notgreater than 1.5 or not greater than 1.2 or not greater than 1 or notgreater than 0.9 or not greater than 0.8 or not greater than 0.7 or notgreater than 0.6 or not greater than 0.5 or not greater than 0.4 or notgreater than 0.3. It will be appreciated that the thickness ratio can bewithin a range, including any of the minimum and maximum values notedabove.

It will be understood that the foregoing ratios apply equally to thoseembodiments having portions that vary in the direction of the length ofthe width. For example, for those embodiments where the body hasportions varying along the length of the body, the first portion canhave an average length (L₁) and the second portion can have an averagelength (L₂), and the portions can have a length ratio, Lr=(L₁/L₂), thatis at least 0.1, such as at least 0.2 or at least 0.3 or at least 0.4 orat least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least0.9 or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or atleast 1.4 or at least 1.5 or at least 1.6 or at least 1.7 or at least1.8 or at least 1.9 or at least 2 or at least 2.2 or at least 2.5 or atleast 2.7 or at least 3 or at least 3.2 or at least 3.5 or at least 4 orat least 5 or at least 6 or at least 7 or at least 8 or at least 9 or atleast 10. Still, at least one non-limiting embodiment, the length ratio,Lr=(L₁/L₂), may be not greater than 10, such as not greater than 9 ornot greater than 8 or not greater than 7 or not greater than 6 or notgreater than 5 or not greater than 4 or not greater than 3 or notgreater than 2.5 or not greater than 2 or not greater than 1.8 or notgreater than 1.5 or not greater than 1.2 or not greater than 1 or notgreater than 0.9 or not greater than 0.8 or not greater than 0.7 or notgreater than 0.6 or not greater than 0.5 or not greater than 0.4 or notgreater than 0.3. It will be appreciated that the length ratio can bewithin a range, including any of the minimum and maximum values notedabove.

For those embodiments where the body has portions varying in thedirection of the width of the body, the first portion can have anaverage width (W₁) and the second portion can have an average width(W₂), and the portions can have a width ratio, Wr=(W₁/W₂), that is atleast 0.1, such as at least 0.2 or at least 0.3 or at least 0.4 or atleast 0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least0.9 or at least 1 or at least 1.1 or at least 1.2 or at least 1.3 or atleast 1.4 or at least 1.5 or at least 1.6 or at least 1.7 or at least1.8 or at least 1.9 or at least 2 or at least 2.2 or at least 2.5 or atleast 2.7 or at least 3 or at least 3.2 or at least 3.5 or at least 4 orat least 5 or at least 6 or at least 7 or at least 8 or at least 9 or atleast 10. Still, at least one non-limiting embodiment, the width ratio,Wr=(W₁/W₂), may be not greater than 10, such as not greater than 9 ornot greater than 8 or not greater than 7 or not greater than 6 or notgreater than 5 or not greater than 4 or not greater than 3 or notgreater than 2.5 or not greater than 2 or not greater than 1.8 or notgreater than 1.5 or not greater than 1.2 or not greater than 1 or notgreater than 0.9 or not greater than 0.8 or not greater than 0.7 or notgreater than 0.6 or not greater than 0.5 or not greater than 0.4 or notgreater than 0.3. It will be appreciated that the width ratio can bewithin a range, including any of the minimum and maximum values notedabove.

The second portion may have a certain average thickness (T₂) that mayfacilitate an improved refractory article. For example, second portion211 may have an average thickness (T₂) at least 1 mm, such as at least 5mm or at least 10 mm or at least 25 mm or at least 50 mm or at least 100mm or at least 200 mm or at least 500 mm. In another embodiment, theaverage thickness (T₂) of the second portion 211 can be not greater than3 m, such as not greater than 2 m or not greater than 1 m or not greaterthan 800 mm or not greater than 500 mm or not greater than 200 mm or notgreater than 100 mm. It will be appreciated that the average thickness(T₂) of the second portion 211 can be within a range including any ofthe minimum and maximum values noted above.

As noted herein, the body 201 may include a third portion 212. Incertain instances, the third portion 212 may be disposed between thefirst portion 210 and second portion 211, and more particularly, may beabutting and in direct contact with the first portion 210 and secondportion 211.

In one aspect, the third portion 212 can include at least one of anoxide and a carbide. For example, third portion 212 may include acombination of materials, including an oxide and a carbide. In anotherembodiment, a third portion 212 can include at least a first phasecomprising a material from a group of silicon carbide (SiC), siliconnitride (Si₃N₄), silicon oxynitride (Si₂ON₂), silica (SiO₂), mullite(3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂), alumina, (Al₂O₃), silicon aluminumoxynitride (SiAlON), or any combination thereof. In more particularembodiments, the third portion 212 may include a first phase comprisingnitride-bonded silicon carbide and a second phase comprising mullite(3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).

The third portion 212 may have a particular ratio of the first phase tothe second phase as defined by a content ratio that may facilitateimproved performance of the refractory article. For example, the thirdportion 212 may have a content ratio, Cr=(C1/C2) of at least 0.1,wherein C1 represents the content (vol %) of the first phase and C2represents the content (vol %) of the second phase, such as at least 0.2or at least 0.3 or at least 0.4 or at least 0.5 or at least 0.6 or atleast 0.7 or at least 0.8 or at least 0.9 or at least 1 or at least 1.1or at least 1.2 or at least 1.3 or at least 1.4 or at least 1.5 or atleast 1.6 or at least 1.7 or at least 1.8 or at least 1.9 or at least 2or at least 2.2 or at least 2.5 or at least 2.7 or at least 3 or atleast 3.2 or at least 3.5 or at least 4 or at least 5 or at least 6 orat least 7 or at least 8 or at least 9 or at least 10. In anotherembodiment, the content ratio Cr=(C1/C2) may be not greater than 10,such as not greater than 9 or not greater than 8 or not greater than 7or not greater than 6 or not greater than 5 or not greater than 4 or notgreater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0.3. It will be appreciated thatthe content ratio of the third portion 212 can be within a rangeincluding any of the minimum and maximum values noted above.

The third portion 212 has a particular average thermal conductivity forimproved performance of the refractory article. For example, the thirdportion 212 may have an average thermal conductivity of not greater than50 W/mK, such as not greater than 45 W/mK or not greater than 40 W/mK ornot greater than 30 W/mK or not greater than 25 W/mK or not greater than20 W/mK or not greater than 18 W/mK or not greater than 15 W/mK. Instill one non-limiting embodiment, the average thermal conductivity ofthe third portion 212 maybe at least 1 W/mK, such as at least 2 W/mK orat least 3 W/mK or at least 4 W/mK or at least 5 W/mK or at least 6 W/mKor at least 7 W/mK or at least 8 W/mK or at least 10 W/mK or at least 12W/mK or at least 14 W/mK or at least 16 W/mK or at least 18 W/mK or atleast 20 W/mK or at least 25 W/mK. It will be appreciated that theaverage thermal conductivity of the third portion 212 can be within arange including any of the minimum and maximum values noted above. Thethermal conductivity of the third portion can be measured according toASTM E1461.

In certain instances, third portion 212 may include a specificcomposition and microstructure. The third portion 212 may include afirst phase comprising silicon carbide and having an average crystallitesize (i.e., grain size) that may facilitate improved performance. Forexample, the third portion 211 may include a polycrystalline first phasehaving an average crystallite size of at least 1 micron, such as atleast 10 microns or at least 25 microns or at least 50 microns or atleast 100 microns or at least 250 microns or at least 500 microns or atleast 1 mm or at least 2 mm or at least 3 mm or at least 4 mm or atleast 5 mm or at least 6 mm or at least 7 mm or at least 8 mm or atleast 9 mm. In another non-limiting embodiment, the first phase of thethird portion 212 may have an average crystallite size of not greaterthan 10 mm, such as not greater than 9 mm or not greater than 8 mm ornot greater than 7 mm or not greater than 6 mm or not greater than 5 mmor not greater than 4 mm or not greater than 3 mm or not greater than 2mm or not greater than 1 mm or not greater than 800 microns or notgreater than 500 microns or not greater than 200 microns or not greaterthan 100 microns or not greater than 50 microns. It will be appreciatedthat the third portion 212 may include a polycrystalline first phasehaving an average crystallite size within a range including any of theminimum and maximum values noted above, such as within a range of atleast 1 micron to not greater than 10 mm. The average crystallite sizecan be measured according to the uncorrected intercept method.

In another embodiment, the third portion 212 may have a second phasecomprising an oxide material having an average crystallite size (i.e.,grain size) that may facilitate improved performance. For example, thethird portion 211 may include a polycrystalline second phase having anaverage crystallite size of at least 1 micron, such as at least 10microns or at least 25 microns or at least 50 microns or at least 100microns or at least 250 microns or at least 500 microns or at least 1 mmor at least 2 mm or at least 3 mm or at least 4 mm or at least 5 mm orat least 6 mm or at least 7 mm or at least 8 mm or at least 9 mm. Inanother non-limiting embodiment, the second phase of the third portion212 may have an average crystallite size of not greater than 10 mm, suchas not greater than 9 mm or not greater than 8 mm or not greater than 7mm or not greater than 6 mm or not greater than 5 mm or not greater than4 mm or not greater than 3 mm or not greater than 2 mm or not greaterthan 1 mm or not greater than 800 microns or not greater than 500microns or not greater than 200 microns or not greater than 100 micronsor not greater than 50 microns. It will be appreciated that the thirdportion 212 may include a polycrystalline second phase having an averagecrystallite size within a range including any of the minimum and maximumvalues noted above, such as within a range of at least 1 micron to notgreater than 10 mm. The average crystallite size can be measuredaccording to the uncorrected intercept method.

In still another aspect, third portion 212 may have an average thickness(T₃) that facilitates the improved performance of the refractoryarticle. For example, the third portion 212 may have an averagethickness of at least 1% of a total thickness (t) of the body 201, suchas at least 5% or at least 10% or at least 20% or at least 30% or atleast 40% or at least 50% of a total thickness (t) of the body 201. Inanother embodiment, the third portion 212 may have an average thickness(T₃) of not greater than 90% of a total thickness (t) of the body 201,such as not greater than 80% or not greater than 70% or not greater than60% or not greater than 50% or not greater than 40% or not greater than30% or not greater than 20% or not greater than 10% or not greater than5% of a total thickness (t) of the body 201. It will be appreciated thatthe average thickness (T₃) of the third portion 212 can be within arange including any of the minimum and maximum values noted above. Asnoted herein, for those embodiments having portions that vary in thedirection of the length, the relative average length of the thirdportion to the total length of the body can be the same as noted abovefor the thickness. Moreover, for those embodiments having portions thatvary in the direction of the width, the relative average width of thethird portion to the total width of the body can be the same as notedabove for the thickness.

In another aspect, the third portion 212 may have a certain averagethickness that may facilitate improved performance of the refractoryarticle. For example, the third portion may have an average thickness ofnot greater than 1 m, such as not greater than 800 mm or not greaterthan 500 mm or not greater than 200 mm or not greater than 100 mm or notgreater than 50 mm or not greater than 20 mm or not greater than 10 mmor not greater than 1 mm or not greater than 500 microns or not greaterthan 100 microns. In another non-limiting embodiment, the third portion212 may have an average thickness (T₃) of at least 1 micron, such as atleast 10 microns or at least 20 microns or at least 30 microns or atleast 50 microns or at least 100 microns or at least 200 microns or atleast 500 microns or at least 1 mm or at least 5 mm or at least 10 mm orat least 25 mm or at least 50 mm or at least 100 mm or at least 200 mmor at least 500 mm. It will be appreciated that the third portion 212may have an average thickness (T₃) within a range including any of theminimum and maximum values noted above.

In certain instances, the body 201 may be formed to have a particularthickness of the different portions relative to each other. For example,the body 201 can have a secondary thickness ratio, 2^(nd) Tr=(T₁/T₃),wherein T₁ is the average thickness of the first portion 210 and T₃ isthe average thickness of the third portion 212. The secondary thicknessratio can be at least 0.1 or at least 0.2 or at least 0.3 or at least0.4 or at least 0.5 or at least 0.6 or at least 0.7 or at least 0.8 orat least 0.9 or at least 1 or at least 1.1 or at least 1.2 or at least1.3 or at least 1.4 or at least 1.5 or at least 1.6 or at least 1.7 orat least 1.8 or at least 1.9 or at least 2 or at least 2.2 or at least2.5 or at least 2.7 or at least 3 or at least 3.2 or at least 3.5 or atleast 4 or at least 5 or at least 6 or at least 7 or at least 8 or atleast 9 or at least 10. In yet another embodiment, the secondarythickness ratio maybe not be greater than 10, such as not greater than 9or not greater than 8 or not greater than 7 or not greater than 6 or notgreater than 5 or not greater than 4 or not greater than 3 or notgreater than 2.5 or not greater than 2 or not greater than 1.8 or notgreater than 1.5 or not greater than 1.2 or not greater than 1 or notgreater than 0.9 or not greater than 0.8 or not greater than 0.7 or notgreater than 0.6 or not greater than 0.5 or not greater than 0.4 or notgreater than 0.3. It will be appreciated that the secondary thicknessratio may be within a range including any of the minimum and maximumvalues noted above. As noted herein, for those embodiments havingportions that vary in the direction of the length, the secondary lengthratio 2^(nd) Lr=(L₁/L₃) can have any of the same values noted above forthe secondary thickness ratio. Moreover, for those embodiments havingportions that vary in the direction of the width, the secondary widthratio 2nd Wr=(W₁/W₃) can have any of the same values noted above for thesecondary thickness ratio.

The body may further include a tertiary thickness ratio as defined bythe relative thickness of the second portion to the third portion. Forexample, the body 201 can have a tertiary thickness ratio, 3^(rd)Tr=(T₂/T₃), wherein T₂ is the average thickness of the second portion211 and T₃ is the average thickness of the third portion 212, of atleast 0.1. In another embodiment, the tertiary thickness ratio can be atleast 0.2, such as or at least 0.3 or at least 0.4 or at least 0.5 or atleast 0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or atleast 1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least1.9 or at least 2 or at least 2.2 or at least 2.5 or at least 2.7 or atleast 3 or at least 3.2 or at least 3.5 or at least 4 or at least 5 orat least 6 or at least 7 or at least 8 or at least 9 or at least 10. Inanother non-limiting embodiment, the body 201 may have a tertiarythickness ratio of not greater than 10 or not greater than 9 or notgreater than 8 or not greater than 7 or not greater than 6 or notgreater than 5 or not greater than 4 or not greater than 3 or notgreater than 2.5 or not greater than 2 or not greater than 1.8 or notgreater than 1.5 or not greater than 1.2 or not greater than 1 or notgreater than 0.9 or not greater than 0.8 or not greater than 0.7 or notgreater than 0.6 or not greater than 0.5 or not greater than 0.4 or notgreater than 0.3. It will be appreciated that the tertiary thicknessratio can be within a range including any of the minimum and maximumvalues noted above. As noted herein, for those embodiments havingportions that vary in the direction of the length, the tertiary lengthratio 3^(rd) Lr=(L₂/L₃) can have any of the same values noted above forthe tertiary thickness ratio. Moreover, for those embodiments havingportions that vary in the direction of the width, the tertiary widthratio 3rd Wr=(W₂/W₃) can have any of the same values noted above for thetertiary thickness ratio.

In still other aspects, the body may have an average Shell Temperatureof not greater than 400° C. The average Shell Temperature defines theheat conducted through the thickness of the body according to a ShellTemperature Test. In at least one embodiment, the body 201 may have anaverage Shell Temperature of not greater than 395° C., such as notgreater than 390° C. or not greater than 385° C. or not greater than380° C. or not greater than 375° C. or not greater than 370° C. or notgreater than 365° C. or not greater than 360° C. or not greater than355° C. or not greater than 350° C. or not greater than 345° C. or notgreater than 340° C. or not greater than 335° C. or not greater than330° C. or not greater than 325° C. Still, in one non-limitingembodiment, the body 201 may have an average Shell Temperature of atleast 100° C. or at least 150° C. or at least 200° C. or at least 250°C. It will be appreciated that the body 201 may have an average ShellTemperature within a range, including any of the minimum and maximumvalues noted above.

The embodiments of FIGS. 2A and 2B are not to be interpreted as limitingthe shape, size, and/or relative dimensions of the body of therefractory articles. For example, FIG. 3 includes an illustration of analternative embodiment. The refractory article 300 includes a body 301including a first portion 310, a second portion 311, and a third portion312 disposed between the first portion 310 and second portion 311. Thebody 301 may include an aperture 315 extending at least partially intothe depth of the body 301 and in certain instances extending through theentire thickness (t) of the body 301.

FIG. 4 includes a perspective view illustration of a refractory articlehaving an alternative shape in accordance with an embodiment. Forexample, the article 400 can include a body 401 having a first portion410, second portion 411, and third portion 412 disposed between thefirst portion 410 and the second portion 411. The body 401 may furtherinclude an exterior surface 417 and a lip 416 extending from the body401, and particularly, the exterior surface 417. The lip 416 may be anannular lip extending through the entire circumference of the body 201.The body 401 may further include an aperture 415, which may be in theform of a central opening extending partially or entirely through thelength L of the body.

The refractory articles of the embodiments herein can be utilized inhigh-temperature applications, such as a foundry or furnace. Forexample, in at least one embodiment, the body of the refractory articlecan be part of the furnace wall. FIG. 5 includes an image of a portionof a furnace, including a burner block 501 as part of the furnace wall502, and a refractory article 503 according to an embodiment. Therefractory article 503 can have any of the features of the embodimentsherein.

FIG. 7 includes a perspective view illustration of a refractory articleaccording to another embodiment. As illustrated, the refractory article700 can have a body 701. The body 701 of FIG. 7 is illustrated as havingan approximately cubicle three-dimensional shape; however, it will beappreciated that other sizes and shapes that the refractory article maybe suitable depending upon the intended application. The body 701 caninclude a plurality of exterior surfaces, including a first exteriorsurface 702 and a second exterior surface 703. The body 701 of therefractory article 700 can have any one feature or combination offeatures of any of the refractory articles of the embodiments herein.

The body 701 can have a first portion 704 defining the first exteriorsurface 702 and a second portion 705 defining the second exteriorsurface 703. In one particular embodiment, the second exterior surface703 includes at least one mounting element 710. In another embodiment,the second exterior surface 703 can include a plurality of mountingelements 710.

The at least one mounting element 710 is suitable for affixing the body701 on the wall of a furnace. More particularly, the at least onemounting element 710 can be part of a complementary mounting assembly,including the at least one mounting element 710 of the body 701 and amounting element of a furnace wall (not depicted). In one embodiment,the at least one mounting element 710 includes at least one of aprotrusion, a groove, a slot, a fixture, a fastener, or any combinationthereof. In the illustrated embodiment of FIG. 7, the mounting elements710 are shown as grooves extending into the body 701 of the secondexterior surface 703. In certain instances, the at least one mountingelement 710 is integral to the body, such as the grooves illustrated inFIG. 7. Still, in another embodiment, the at least one mounting element710 can be a releasably secured component, such as a bracket, fixture,or fastener releasably secured to the second exterior surface 703 of thebody 701.

The position of the at least one mounting element 710 on the body mayeliminate the need for intermediate mounting components used inconventional refractory articles. The at least one mounting element 710can be on the second exterior surface 703, and more particularly, may beintegral within the second exterior surface 703. In one particularembodiment, the plurality of mounting elements 710 can be spaced apartfrom each other on the second exterior surface 703. For example, asillustrated in FIG. 7, the plurality of mounting elements are spacedaround a peripheral edge 711 joining the second exterior surface and anexterior side surface 712 of the body 701.

Many different aspects and embodiments are possible. Some of thoseaspects and embodiments are described herein. After reading thisspecification, skilled artisans will appreciate that those aspects andembodiments are only illustrative and do not limit the scope of thepresent invention. Embodiments may be in accordance with any one or moreof the embodiments as listed below.

EMBODIMENTS

Embodiment 1. A refractory article comprising:

a body including:a first portion defining at least a portion of a first exterior surfaceof the body, wherein the first portion comprises a carbide;a second portion defining at least a portion of a second exteriorsurface of the body opposite the first exterior surface, wherein thesecond portion comprises an oxide;a thermal conductivity difference (ΔTC) of at least 10 W/mK between thefirst exterior surface and the second exterior surface; and an averageShell Temperature of not greater than 400° C.

Embodiment 2. A refractory article comprising:

a body including:a first portion defining at least a portion of a first exterior surfaceof the body, wherein the first portion comprises a carbide;a second portion defining at least a portion of a second exteriorsurface of the body opposite the first exterior surface and having anaverage thickness of at least 5% of the total thickness of the body,wherein the second portion comprises an oxide; anda thermal conductivity difference of at least 10 W/mK between the firstexterior surface and the second exterior surface.

Embodiment 3. A refractory article comprising:

a body including:a first portion defining at least a portion of a first exterior surfaceof the body, wherein the first portion comprises a carbide;a second portion defining at least a portion of a second exteriorsurface of the body opposite the first exterior surface, wherein thesecond portion includes a majority content (vol %) of a polycrystallineoxide material; anda thermal conductivity difference of at least 10 W/mK at 300 K betweenthe first exterior surface and the second exterior surface.

Embodiment 4. The refractory article of any one of embodiments 1, 2, and3, wherein the first portion comprises silicon carbide.

Embodiment 5. The refractory article of any one of embodiments 1, 2, and3, wherein the first portion comprises at least one material from thegroup of oxygen, nitrogen, compounds thereof, or any combinationthereof.

Embodiment 6. The refractory article of any one of embodiments 1, 2, and3, wherein the first portion comprises a primary phase including siliconcarbide and a secondary phase comprising a nitrogen-containingcomposition.

Embodiment 7. The refractory article of embodiment 6, wherein the firstportion has a content ratio Cr1=(SC2/PC1) of at least 0.1, wherein PC1is the content (vol %) of the primary phase, and SC2 is the content (vol%) of the secondary phase, wherein the content ratio of the firstportion (Cr1) can be at least 0.001 or at least 0.01 or at least 0.1 orat least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1 or atleast 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least 1.9 orat least 2 or at least 2.2 or at least 2.5 or at least 2.7 or at least 3or at least 3.2 or at least 3.5 or at least 4 or at least 5 or at least6 or at least 7 or at least 8 or at least 9 or at least 10.

Embodiment 8. The refractory article of embodiment 6, the first portionhas a content ratio Cr1=(SC2/PC1) of not greater than 1000, wherein PC1is the content (vol %) of the primary phase and SC2 is the content (vol%) of the secondary phase, wherein the content ratio of the firstportion (Cr1) can be not greater than 100 or not greater than 10 or notgreater than 9 or not greater than 8 or not greater than 7 or notgreater than 6 or not greater than 5 or not greater than 4 or notgreater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0.3.

Embodiment 9. The refractory article of any one of embodiments 1, 2, and3, wherein the first portion comprises nitride-bonded silicon carbide.

Embodiment 10. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion consists essentially of nitride-bondedsilicon carbide.

Embodiment 11. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises oxynitride-bonded siliconcarbide.

Embodiment 12. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion consists essentially ofoxynitride-bonded silicon carbide.

Embodiment 13. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion consists essentially of siliconcarbide.

Embodiment 14. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises an average thermalconductivity of at least 10 W/mK or at least 11 W/mK or at least 12 W/mKor at least 13 W/mK or at least 14 W/mK or at least 15 W/mK or at least16 W/mK or at least 17 W/mK or at least 18 W/mK or at least 20 W/mK orat least 25 W/mK or at least 30 W/mK or at least 35 W/mK or at least 40W/mK or at least 45 W/mK or at least 50 W/mK or at least 55 W/mK or atleast 60 W/mK or at least 65 W/mK or at least 70 W/mK or at least 80W/mK or at least 90 W/mK or at least 100 W/mK.

Embodiment 15. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprise an average thermalconductivity of not greater than 200 W/mK or not greater than 180 W/mKor not greater than 160 W/mK or not greater than 140 W/mK or not greaterthan 120 W/mK or not greater than 100 W/mK or not greater than 90 W/mKor not greater than 80 W/mK or not greater than 70 W/mK or not greaterthan 60 W/mK or not greater than 50 W/mK or not greater than 45 W/mK ornot greater than 40 W/mK or not greater than 35 W/mK or not greater than30 W/mK or not greater than 25 W/mK or not greater than 22 W/mK or notgreater than 20 W/mK.

Embodiment 16. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises a primary phase comprisingsilicon carbide having an average crystallite size within a range of atleast 1 micron to not greater than 10 mm.

Embodiment 17. The refractory article of any one of embodiments 1 and 3,wherein the first portion comprises an average thickness of at least 5%of the total thickness of the body.

Embodiment 18. The refractory article of any one of embodiments 2 and17, wherein the first portion comprises an average thickness of at least10% of a total thickness of the body or at least 20% or at least 30% orat least 40% or at least 50% or at least 60% or at least 70% or at least80% of a total thickness of the body.

Embodiment 19. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises an average thickness of notgreater than 90% of a total thickness of the body or not greater than80% or not greater than 70% or not greater than 60% or not greater than50% or not greater than 40% or not greater than 30% or not greater than20% of a total thickness of the body.

Embodiment 20. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises an average thickness of atleast 1 mm or at least 5 mm or at least 10 mm or at least 25 mm or atleast 50 mm or at least 100 mm or at least 200 mm or at least 500 mm.

Embodiment 21. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises an average thickness of notgreater than 10 m or not greater than 5 m or not greater than 3 m or notgreater than 1 m or not greater than 800 mm or not greater than 500 mmor not greater than 200 mm or not greater than 100 mm.

Embodiment 22. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion defines not greater than 90% of a totalexterior surface area of the body or not greater than 80% or not greaterthan 70% or not greater than 60% or not greater than 50% or not greaterthan 40% or not greater than 30% or not greater than 20% or not greaterthan 10%.

Embodiment 23. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion defines at least 1% of a total exteriorsurface area of the body or at least 5% or at least 10% or at least 20%or at least 30% or at least 40% or at least 50% or at least 60% or atleast 70% or at least 80%.

Embodiment 24. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises alumina and silica.

Embodiment 25. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises an aluminosilicate.

Embodiment 26. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises mullite (3Al₂O₃-2SiO₂ or2Al₂O₃—SiO₂).

Embodiment 27. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion consists essentially of mullite(3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).

Embodiment 28. The refractory article of any one of embodiments 1 and 2,wherein the second portion includes a majority content (vol %) of apolycrystalline oxide material.

Embodiment 29. The refractory article of any one of embodiments 3 and28, wherein the second portion includes at least 60 vol % of apolycrystalline oxide material for a total volume of the second portionor at least 70 vol % or at least 80 vol % or at least 90 vol % or atleast 95 vol % of a polycrystalline oxide material for a total volume ofthe second portion.

Embodiment 30. The refractory article of any one of embodiments 3 and28, wherein the second portion consists essentially of polycrystallineoxide material.

Embodiment 31. The refractory article of any one of embodiments 3 and28, wherein the second portion includes at least 60 vol % of apolycrystalline mullite for a total volume of the second portion or atleast 70 vol % or at least 80 vol % or at least 90 vol % or at least 95vol % of a polycrystalline mullite for a total volume of the secondportion.

Embodiment 32. The refractory article of any one of embodiments 3 and28, wherein the second portion consists essentially of polycrystallinemullite.

Embodiment 33. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion is essentially free of an amorphousphase material.

Embodiment 34. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises an average thermalconductivity of not greater than 10 W/mK or not greater than 8 W/mK ornot greater than 7 W/mK or not greater than 6 W/mK or not greater than 5W/mK or not greater than 4 W/mK or not greater than 2 W/mK or notgreater than 1 W/mK.

Embodiment 35. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises an average thermalconductivity of at least 0.5 W/mK or at least 1 W/mK or at least 2 W/mKor at least 3 W/mK or at least 4 W/mK or at least 5 W/mK or at least 6W/mK or at least 7 W/mK or at least 8 W/mK.

Embodiment 36. The refractory article of any one of embodiments 1, 2,and 3, further comprising a thermal conductivity difference ΔTC=TC1−TC2of not greater than 200 W/mK, wherein TC1 is the average thermalconductivity of the first portion, and TC2 is the average thermalconductivity of the second portion, wherein the thermal conductivitydifference ΔTC is not greater than 180 W/mK or not greater than 160 W/mKor not greater than 140 W/mK or not greater than 120 W/mK or not greaterthan 100 W/mK or not greater than 90 W/mK or not greater than 80 W/mK ornot greater than 70 W/mK or not greater than 60 W/mK or not greater than50 W/mK or not greater than 45 W/mK or not greater than 40 W/mK or notgreater than 35 W/mK or not greater than 30 W/mK or not greater than 25W/mK or not greater than 22 W/mK or not greater than 20 W/mK.

Embodiment 37. The refractory article of any one of embodiments 1, 2,and 3, further comprising a thermal conductivity difference ΔTC=TC1-TC2of at least 12 W/mK, wherein TC1 is the average thermal conductivity ofthe first portion, and TC2 is the average thermal conductivity of thesecond portion, wherein the thermal conductivity difference ΔTC is atleast 13 W/mK or at least 14 W/mK or at least 15 W/mK or at least 16W/mK or at least 17 W/mK or at least 18 W/mK or at least 20 W/mK or atleast 25 W/mK or at least 30 W/mK or at least 35 W/mK or at least 40W/mK or at least 45 W/mK or at least 50 W/mK or at least 55 W/mK or atleast 60 W/mK or at least 70 W/mK or at least 80 W/mK or at least 90W/mK or at least 100 W/mK.

Embodiment 38. The refractory article of any one of embodiments 1, 2,and 3, further comprising a coefficient of thermal expansion difference(ΔCTE=CTE1-CTE2) of not greater than 5 10⁻⁶/° C., wherein CTE1 is theaverage coefficient of thermal expansion of the first portion and CTE2is the average coefficient of thermal expansion of the second portion ornot greater than 4.8×10⁻⁶/° C. or not greater than 4.6×10⁻⁶/° C. or notgreater than 4.4×10⁻⁶/° C. or not greater than 4.2×10⁻⁶/° C. or notgreater than 4×10⁻⁶/° C. or not greater than 3.8×10⁻⁶/° C. or notgreater than 3.6×10⁻⁶/° C. or not greater than 3.4×10⁻⁶/° C. or notgreater than 3.2×10⁻⁶/° C. or not greater than 3×10⁻⁶/° C. or notgreater than 2.9×10⁻⁶/° C. or not greater than 2.8×10⁻⁶/° C. or notgreater than 2.7×10⁻⁶/° C. or not greater than 2.6×10⁻⁶/° C. or notgreater than 2.5×10⁻⁶/° C. or not greater than 2.4×10⁻⁶/° C. or notgreater than 2.3×10⁻⁶/° C. or not greater than 2.2×10⁻⁶/° C. or notgreater than 2.1×10⁻⁶/° C. or not greater than 2×10⁻⁶/° C. or notgreater than 1.9×10⁻⁶/° C. or not greater than 1.8×10⁻⁶/° C. or notgreater than 1.7×10⁻⁶/° C. or not greater than 1.6×10⁻⁶/° C. or notgreater than 1.5×10⁻⁶/° C. or not greater than 1.4×10⁻⁶/° C. or notgreater than 1.3×10⁻⁶/° C. or not greater than 1.2×10⁻⁶/° C. or notgreater than 1.1×10⁻⁶/° C. or not greater than 1×10⁻⁶/° C. or notgreater than 0.9×10⁻⁶/° C. or not greater than 0.8×10⁻⁶/° C. or notgreater than 0.7×10⁻⁶/° C. or not greater than 0.6×10⁻⁶/° C. or notgreater than 0.5×10⁻⁶/° C. or not greater than 0.4×10⁻⁶/° C. or notgreater than 0.3×10⁻⁶/° C. or not greater than 0.2×10⁻⁶/° C. or notgreater than 0.1×10⁻⁶/° C.

Embodiment 39. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises a polycrystalline phasehaving an average crystallite size within a range of at least 1 micronto not greater than 10 mm.

Embodiment 40. The refractory article of any one of embodiments 1 and 3,wherein the second portion comprises an average thickness of at least 5%of a total thickness of the body.

Embodiment 41. The refractory article of any one of embodiments 2 and40, wherein the second portion comprises an average thickness of atleast 6% of a total thickness of the body or at least 7% or at least 8%or at least 9% or at least 10% or at least 15% or at least 20% or atleast 25% or at least 30% or at least 35% or at least 40% or at least50% or at least 55% or at least 60% of a total thickness of the body.

Embodiment 42. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion comprises an average thickness of notgreater than 90% of a total thickness of the body or not greater than80% or not greater than 70% or not greater than 60% or not greater than50% or not greater than 40% or not greater than 30% or not greater than20% or not greater than 10% of a total thickness of the body.

Embodiment 43. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises a first average thickness(T1) and the second portion comprises a second average thickness (T2),and wherein the body comprises a thickness ratio Tr=(T1/T2) that is atleast 0.1 or at least 0.2 or at least 0.3 or at least 0.4 or at least0.5 or at least 0.6 or at least 0.7 or at least 0.8 or at least 0.9 orat least 1 or at least 1.1 or at least 1.2 or at least 1.3 or at least1.4 or at least 1.5 or at least 1.6 or at least 1.7 or at least 1.8 orat least 1.9 or at least 2 or at least 2.2 or at least 2.5 or at least2.7 or at least 3 or at least 3.2 or at least 3.5 or at least 4 or atleast 5 or at least 6 or at least 7 or at least 8 or at least 9 or atleast 10.

Embodiment 44. The refractory article of any one of embodiments 1, 2,and 3, wherein the first portion comprises a first average thickness(T1) and the second portion comprises a second average thickness (T2)and wherein the body comprises a thickness ratio Tr=(T1/T2) that is notgreater than 10 or not greater than 9 or not greater than 8 or notgreater than 7 or not greater than 6 or not greater than 5 or notgreater than 4 or not greater than 3 or not greater than 2.5 or notgreater than 2 or not greater than 1.8 or not greater than 1.5 or notgreater than 1.2 or not greater than 1 or not greater than 0.9 or notgreater than 0.8 or not greater than 0.7 or not greater than 0.6 or notgreater than 0.5 or not greater than 0.4 or not greater than 0.3.

Embodiment 45. The refractory article of any one of embodiments 1 and 3,wherein the second portion comprises an average thickness of at least 1mm.

Embodiment 46. The refractory article of any one of embodiments 2 and45, wherein the second portion comprises an average thickness of atleast 5 mm or at least 10 mm or at least 25 mm or at least 50 mm or atleast 100 mm or at least 200 mm or at least 500 mm.

Embodiment 47. The refractory article of any one of embodiments 2 and45, wherein the second portion comprises an average thickness of notgreater 3 m or not greater than 2 m or not greater than 1 m or notgreater than 800 mm or not greater than 500 mm or not greater than 200mm or not greater than 100 mm.

Embodiment 48. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion defines not greater than 90% of atotal exterior surface area of the body or not greater than 80% or notgreater than 70% or not greater than 60% or not greater than 50% or notgreater than 40% or not greater than 30% or not greater than 20% or notgreater than 10%.

Embodiment 49. The refractory article of any one of embodiments 1, 2,and 3, wherein the second portion defines at least 1% of a totalexterior surface area of the body or at least 5% or at least 10% or atleast 20% or at least 30% or at least 40% or at least 50% or at least60% or at least 70% or at least 80%.

Embodiment 50. The refractory article of any one of embodiments 1, 2,and 3 further comprising a third portion disposed between the firstportion and the second portion.

Embodiment 51. The refractory article of embodiment 50, wherein thethird portion comprises at least one of an oxide and a carbide.

Embodiment 52. The refractory article of embodiment 50, wherein thethird portion comprises an oxide and a carbide.

Embodiment 53. The refractory article of embodiment 50, wherein thethird portion comprises at least a first phase comprising a materialselected from the group of silicon carbide (SiC), silicon nitride(Si₃N₄), silicon oxynitride (Si₂ON₂), silica (SiO₂), mullite(3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂), alumina, (Al₂O₃), silicon aluminumoxynitride (SiAlON), or any combination thereof.

Embodiment 54. The refractory article of embodiment 50, wherein thethird portion comprises a first phase comprising nitride-bonded siliconcarbide and a second phase comprising mullite (3Al₂O₃-2SiO₂ or2Al₂O₃—SiO₂).

Embodiment 55. The refractory article of embodiment 50, wherein thethird portion comprises a first phase in a first content (C1) (vol %)and a second phase in a second content (C2) (vol %) and wherein thethird phase comprises a content ratio Cr=(C1/C2) of at least 0.1 or atleast 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1 or atleast 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least 1.9 orat least 2 or at least 2.2 or at least 2.5 or at least 2.7 or at least 3or at least 3.2 or at least 3.5 or at least 4 or at least 5 or at least6 or at least 7 or at least 8 or at least 9 or at least 10.

Embodiment 56. The refractory article of embodiment 50, wherein thethird portion comprises a first phase in a first content (C1) (vol %)and a second phase in a second content (C2) (vol %) and wherein thethird phase comprises a content ratio Cr=(C1/C2) of not greater than 10or not greater than 9 or not greater than 8 or not greater than 7 or notgreater than 6 or not greater than 5 or not greater than 4 or notgreater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0.3.

Embodiment 57. The refractory article of embodiment 50, wherein thethird portion comprise an average thermal conductivity of not greaterthan 50 W/mK or not greater than 45 W/mK or not greater than 40 W/mK ornot greater than 30 W/mK or not greater than 25 W/mK or not greater than20 W/mK or not greater than 18 W/mK or not greater than 15 W/mK.

Embodiment 58. The refractory article of embodiment 50, wherein thethird portion comprises an average thermal conductivity of at least 1W/mK or at least 2 W/mK or at least 3 W/mK or at least 4 W/mK or atleast 5 W/mK or at least 6 W/mK or at least 7 W/mK or at least 8 W/mK orat least 10 W/mK or at least 12 W/mK or at least 14 W/mK or at least 16W/mK or at least 18 W/mK or at least 20 W/mK or at least 25 W/mK.

Embodiment 59. The refractory article of embodiment 50, wherein thethird portion comprises a first phase comprising silicon carbide havingan average crystallite size within a range of at least 1 micron to notgreater than 10 mm.

Embodiment 60. The refractory article of embodiment 50, wherein thethird portion comprises a second phase comprising an oxide having anaverage crystallite size within a range of at least 1 micron to notgreater than 10 mm.

Embodiment 61. The refractory article of embodiment 50, wherein thethird portion comprises an average thickness of at least 1% of a totalthickness of the body or at least 5% or at least 10% or at least 20% orat least 30% or at least 40% or at least 50% of a total thickness of thebody.

Embodiment 62. The refractory article of embodiment 50, wherein thethird portion comprises an average thickness of not greater than 90% ofa total thickness of the body or not greater than 80% or not greaterthan 70% or not greater than 60% or not greater than 50% or not greaterthan 40% or not greater than 30% or not greater than 20% or not greaterthan 10% or not greater than 5% of a total thickness of the body.

Embodiment 63. The refractory article of embodiment 50, wherein thethird portion comprises an average thickness of not greater than 1 m ornot greater than 800 mm or not greater than 500 mm or not greater than200 mm or not greater than 100 mm or not greater than 50 mm or notgreater than 20 mm or not greater than 10 mm or not greater than 1 mm ornot greater than 500 microns or not greater than 100 microns.

Embodiment 64. The refractory article of embodiment 50, wherein thethird portion comprises an average thickness of at least 1 micron or atleast 10 microns or at least 20 microns or at least 30 microns or atleast 50 microns or at least 100 microns or at least 200 microns or atleast 500 microns or at least 1 mm or at least 5 mm or at least 10 mm orat least 25 mm or at least 50 mm or at least 100 mm or at least 200 mmor at least 500 mm.

Embodiment 65. The refractory article of embodiment 50, wherein thefirst portion comprises a first average thickness (T1), and the thirdportion comprises a third average thickness (T3), and wherein the bodycomprises a secondary thickness ratio 2nd Tr=(T1/T3) of at least 0.1 orat least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or at least0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1 or atleast 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or at least1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least 1.9 orat least 2 or at least 2.2 or at least 2.5 or at least 2.7 or at least 3or at least 3.2 or at least 3.5 or at least 4 or at least 5 or at least6 or at least 7 or at least 8 or at least 9 or at least 10.

Embodiment 66. The refractory article of embodiment 50, wherein thefirst portion comprises a first average thickness (T1), and the thirdportion comprises a third average thickness (T3), and wherein the bodycomprises a secondary thickness ratio 2nd Tr=(T1/T3) of not greater than10 or not greater than 9 or not greater than 8 or not greater than 7 ornot greater than 6 or not greater than 5 or not greater than 4 or notgreater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0.3.

Embodiment 67. The refractory article of embodiment 50, wherein thesecond portion comprises a second average thickness (T2), and the thirdportion comprises a third average thickness (T3), and wherein the bodycomprises a tertiary thickness ratio 3^(rd) Tr=(T2/T3) of at least 0.1or at least 0.2 or at least 0.3 or at least 0.4 or at least 0.5 or atleast 0.6 or at least 0.7 or at least 0.8 or at least 0.9 or at least 1or at least 1.1 or at least 1.2 or at least 1.3 or at least 1.4 or atleast 1.5 or at least 1.6 or at least 1.7 or at least 1.8 or at least1.9 or at least 2 or at least 2.2 or at least 2.5 or at least 2.7 or atleast 3 or at least 3.2 or at least 3.5 or at least 4 or at least 5 orat least 6 or at least 7 or at least 8 or at least 9 or at least 10.

Embodiment 68. The refractory article of embodiment 50, wherein thesecond portion comprises a second average thickness (T2), and the thirdportion comprises a third average thickness (T3), and wherein the bodycomprises a tertiary thickness ratio 3^(rd) Tr=(T2/T3) of not greaterthan 10 or not greater than 9 or not greater than 8 or not greater than7 or not greater than 6 or not greater than 5 or not greater than 4 ornot greater than 3 or not greater than 2.5 or not greater than 2 or notgreater than 1.8 or not greater than 1.5 or not greater than 1.2 or notgreater than 1 or not greater than 0.9 or not greater than 0.8 or notgreater than 0.7 or not greater than 0.6 or not greater than 0.5 or notgreater than 0.4 or not greater than 0.3.

Embodiment 69. The refractory article of any one of embodiments 2 and 3,wherein the body comprises an average Shell Temperature of not greaterthan 400° C.

Embodiment 70. The refractory article of any one of embodiments 1 and69, wherein the body comprises an average Shell Temperature of notgreater than 395° C. or not greater than 390° C. or not greater than385° C. or not greater than 380° C. or not greater than 375° C. or notgreater than 370° C. or not greater than 365° C. or not greater than360° C. or not greater than 355° C. or not greater than 350° C. or notgreater than 345° C. or not greater than 340° C. or not greater than335° C. or not greater than 330° C. or not greater than 325° C.

Embodiment 71. The refractory article of any one of embodiments 1 and69, wherein the body comprises an average Shell Temperature of at least100° C. or at least 150° C. or at least 200° C. or at least 250° C.

Embodiment 72. The refractory article of any one of embodiments 1, 2,and 3, wherein the body is part of a furnace wall.

Embodiment 73. The refractory article of any one of embodiments 1, 2,and 3, wherein the body further comprises a central opening extendingthrough the body.

Embodiment 74. The refractory article of any one of embodiments 1, 2,and 3, wherein the body further comprises an annular lip extending froma major surface of the body.

Embodiment 75. A furnace including the refractory article of any one ofembodiments 1, 2, and 3.

Embodiment 76. A system comprising:

a furnace including a furnace wall defining a volume for heatingmaterial, wherein the furnace wall comprises at least one refractorycomprising:a body including:a first portion defining at least a portion of a first exterior surfaceof the body, wherein the first portion comprises a carbide;a second portion defining at least a portion of a second exteriorsurface of the body opposite the first exterior surface, wherein thesecond portion comprises an oxide;a thermal conductivity difference of at least 10 W/mK between the firstexterior surface and the second exterior surface; andan average Shell Temperature of not greater than 400° C.

Embodiment 77. A method of forming a refractory article comprising:

placing a first material into a production tool;placing a second material into the production tool;forming a green body having a first portion including the first materialand a second portion including the second material; andforming a refractory article from the green body, wherein the refractorybody comprises: a first portion defining at least a portion of a firstexterior surface of the body, wherein the first portion comprises acarbide;a second portion defining at least a portion of a second exteriorsurface of the body opposite the first exterior surface, wherein thesecond portion comprises an oxide.

Embodiment 78. The method of embodiment 77, wherein placing the firstmaterial into a production tool includes depositing the first materialinto a cavity in the production tool, and wherein placing the secondmaterial into the production tool includes depositing the secondmaterial onto the first material into the cavity of the production tool.

Embodiment 79. The method of embodiment 77, wherein the first materialis a dry powder mixture.

Embodiment 80. The method of embodiment 77, wherein the first materialis a wet mixture including a particulate material contained in a liquidcarrier.

Embodiment 81. The method of embodiment 77, wherein the second materialis a dry powder mixture.

Embodiment 82. The method of embodiment 77, wherein the second materialis a wet mixture including a particulate material contained in a liquidcarrier.

Embodiment 83. The method of embodiment 77, wherein the first materialincludes at least one material selected from the group of siliconcarbide (SiC), silicon metal (Si), silica (SiO₂), silicon nitride(Si₃N₄), or any combination thereof.

Embodiment 84. The method of embodiment 77, wherein the second materialincludes an oxide.

Embodiment 85. The method of embodiment 77, wherein the second materialincludes alumina.

Embodiment 86. The method of embodiment 77, wherein the second materialincludes silica.

Embodiment 87. The method of embodiment 77, wherein the second materialincludes an aluminosilicate.

Embodiment 88. The method of embodiment 77, wherein the process furtherincludes placing a third material into the production tool, wherein thethird material is disposed between the first material and the secondmaterial.

Embodiment 89. The method of embodiment 88, wherein the third materialis a dry powder mixture.

Embodiment 90. The method of embodiment 88, wherein the third materialis a wet mixture including a particulate material contained in a liquidcarrier.

Embodiment 91. The method of embodiment 88, wherein the third materialincludes a mixture of the first material and the second material.

Embodiment 92. The method of embodiment 77, wherein forming the greenbody, includes at least one process selected from the group consistingof molding, casting, pressing, drying, cooling, heating, irradiating,additive manufacturing, or any combination thereof.

Embodiment 93. The method of embodiment 88, wherein forming the greenbody and the refractory article is completed in a single forming processin a single processing vessel.

Embodiment 94. The method of embodiment 77, wherein forming therefractory article includes firing the green body at a firingtemperature within a range of at least 1200° C. to not greater than2000° C.

Embodiment 95. The method of embodiment 77, wherein forming therefractory article includes firing the green body in at least oneatmospheric condition from the group of inert, oxidizing, reducing, ornitrogen-rich, or any combination thereof.

Embodiment 96. The method of embodiment 77, wherein forming therefractory article includes co-firing the first portion and secondportion.

Embodiment 97. The method of embodiment 77, wherein forming therefractory article includes forming a diffusion region between the firstportion and the second portion defined by the interdiffusion of speciesfrom the first and second portions during sintering, wherein thediffusion region defines a third portion of the body.

Embodiment 98. The refractory article of any one of embodiments 1, 2,and 3, wherein the second exterior surface comprises at least onemounting element.

Embodiment 99. The refractory article of embodiment 98, wherein the atleast one mounting element includes at least one of a protrusion, agroove, a slot, a fixture, a fastener, or any combination thereof.

Embodiment 100. The refractory article of embodiment 98, wherein the atleast one mounting element is integral to the body.

Embodiment 101. The refractory article of embodiment 98, wherein the atleast one mounting element is one part of a complementary mountingassembly, including the at least one mounting element of the body and amounting element of a furnace wall.

Embodiment 102. The refractory article of embodiment 98, wherein thebody comprises a plurality of mounting elements spaced apart from eachother on the second exterior surface.

Embodiment 103. The refractory article of embodiment 102, wherein theplurality of mounting elements are spaced around a peripheral edgejoining the second exterior surface and an exterior side surface of thebody.

EXAMPLES Example 1

A first powder mixture was made with the following proportion of drypowder ingredients: 84.2% black silicon carbide; 0.5% boron carbide;9.0% silicon metal; 6.0% silica fume; 0.2% limestone. The black siliconcarbide powder is available from Saint Gobain Corporation. At leastabout 90% of the black silicon carbide powder particles have a size inthe range of about 50 microns to about 5 mm.

An organic binder solution of methylcellulose in water was added to thefirst powder mixture while mixing in a high-intensity mixer until asubstantially uniform mass was obtained. The amount of organic bindersolution added was sufficient to cause the mixture to be moldable. Thebinder is temporary, as it is partially or completely eliminated duringdrying and firing steps.

The mixed first material was then placed in the cavity of a mold andcompacted under a pressurized ram.

A second material, having mullite powder as the major component, wasobtained from Washington Mills. The second powder and has an averageparticle size of around 0.38 mm. Alumina and clay powders are added tothe mix to give a final composition of 79% alumina and 20% silica. Anorganic binder mixture and water were added to the powders while mixingin a high-intensity mixer until a substantially uniform mass wasobtained.

A third material was formed and included a mixture of the first materialand second material in a ratio of 1:1 (i.e., 50 wt % of the firstmaterial and 50 wt % of the second material).

The third material was deposited into the mold cavity on the firstmaterial and compacted in the same manner as the first material. Thesecond material was deposited into the cavity of the mold onto the thirdmaterial and compacted in the same manner as the first and thirdmaterials. The result was a green body including a combination of thefirst material, second material, and third material disposed between thefirst material and the second material. The green body was removed fromthe mold and dried at 93° C. to remove the water before firing.

The dried green body was then fired in a kiln. The firing was carriedout in a nitrogen atmosphere (>99% nitrogen) with a peak temperature of1430° C. After conducting a sufficient firing in the nitrogenatmosphere, the atmosphere is changed to an oxidizing atmosphere.

FIG. 6 includes a perspective view image of the refractory article ofExample 1. The refractory article includes a first portion 601,consisting of silicon oxynitride-bonded silicon carbide, including 18 wt% silicon oxynitride and 80 wt % silicon carbide. The total averagethickness of the body is approximately 28.5 cm, and the averagethickness of the first portion 601 is approximately 16 cm. The firstportion 601 has a thermal conductivity of approximately 19.2 W/mK at1200° C. and a coefficient of thermal expansion of approximately5×10⁻⁶/° C. up to 1500° C. The first phase of silicon carbide includescrystallites having an average grain size of approximately 0.23 mm.

The second portion 602 consists predominantly of mullite. The averagethickness of the second portion 602 is approximately 11 cm. The secondportion 602 has a thermal conductivity of approximately 1.73 W/mK at1200° C. and a coefficient of thermal expansion of approximately4.6×10⁻⁶/° C. up to 1500° C. The mullite includes crystallites having anaverage grain size of approximately 0.38 mm. The exterior surface 607was made entirely of the second portion 602.

The third portion 603 consists of a mixture of oxynitride bonded siliconcarbide and mullite in a 1:1 relative content. The average thickness ofthe third portion 603 is approximately 1.3 cm. The third portion 603 hada coefficient of thermal expansion of approximately 4.8×10⁻⁶/° C. Themullite includes crystallites having an average grain size ofapproximately 0.38 mm. The silicon carbide phase includes crystalliteshaving an average grain size of approximately 0.23 mm. The third portion603 is disposed between and abutting the first portion 601 and secondportion 602. The third portion 603 is spaced apart from the exteriorsurfaces 605 and 607.

The present embodiments represent a departure from the state of the art.The tests on the refractory articles of embodiments herein revealremarkable and unexpected performance by utilization of one or more ofthe features of the embodiments herein. Notably, without wishing to betied to a particular theory, it is noted that certain features of therefractory articles of the embodiments herein facilitate the improvedcombination of thermal properties (e.g., thermal shock resistance,thermal conductivity, etc.) and mechanical properties (e.g., dimensionalstability as demonstrated by limited growth and warpage) compared toconventional refractory articles.

Note that not all of the activities described above in the generaldescription or the examples are required, that a portion of a specificactivity may not be required, and that one or more further activitiesmay be performed in addition to those described. Still further, theorder in which activities are listed is not necessarily the order inwhich they are performed.

Benefits, other advantages, and solutions to problems have beendescribed above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims. Many different aspects and embodimentsare possible. Some of those aspects and embodiments are describedherein. After reading this specification, skilled artisans willappreciate that those aspects and embodiments are only illustrative anddo not limit the scope of the present invention. Additionally, thoseskilled in the art will understand that some embodiments that includeanalog circuits can be similarly implemented using digital circuits andvice versa.

The specification and illustrations of the embodiments described hereinare intended to provide a general understanding of the structure of thevarious embodiments. The specification and illustrations are notintended to serve as an exhaustive and comprehensive description of allof the elements and features of apparatus and systems that use thestructures or methods described herein. Separate embodiments may also beprovided in combination in a single embodiment, and conversely, variousfeatures that are, for brevity, described in the context of a singleembodiment, may also be provided separately or in any subcombination.Further, reference to values stated in ranges includes each and everyvalue within that range. Many other embodiments may be apparent toskilled artisans only after reading this specification. Otherembodiments may be used and derived from the disclosure, such that astructural substitution, logical substitution, or another change may bemade without departing from the scope of the disclosure. Accordingly,the disclosure is to be regarded as illustrative rather thanrestrictive. Benefits, other advantages, and solutions to problems havebeen described above with regard to specific embodiments. However, thebenefits, advantages, solutions to problems, and any feature(s) that maycause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeature of any or all the claims.

The Abstract of the Disclosure is provided to comply with Patent Law andis submitted with the understanding that it will not be used tointerpret or limit the scope or meaning of the claims. In addition, inthe foregoing Detailed Description of the Drawings, various features maybe grouped together or described in a single embodiment for the purposeof streamlining the disclosure. This disclosure is not to be interpretedas reflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, the inventive subject matter may be directedto less than all features of any of the disclosed embodiments. Thus, thefollowing claims are incorporated into the Detailed Description of theDrawings, with each claim standing on its own as defining separatelyclaimed subject matter.

What is claimed is:
 1. A refractory article, comprising a bodyincluding: a first portion defining at least a portion of a firstexterior surface of the body, wherein the first portion comprises acarbide; a second portion defining at least a portion of a secondexterior surface of the body opposite the first exterior surface,wherein the second portion includes a majority content (vol %) of apolycrystalline oxide material; and a thermal conductivity difference ofat least 10 W/mK at 300 K between the first exterior surface and thesecond exterior surface.
 2. The refractory article of claim 1, whereinthe first portion includes an entirety of the first exterior surface ofthe body, and the second portion includes an entirety of the secondexterior surface of the body.
 3. The refractory article of claim 1,wherein the first portion comprises silicon carbide.
 4. The refractoryarticle of claim 1, wherein the first portion comprises at least onematerial from the group of oxygen, nitrogen, compounds thereof, or anycombination thereof.
 5. The refractory article of claim 1, wherein thefirst portion comprises a primary phase including silicon carbide and asecondary phase comprising a nitrogen-containing composition.
 6. Therefractory article of claim 1, wherein the first portion comprisesnitride-bonded silicon carbide or oxynitride-bonded silicon carbide. 7.The refractory article of claim 1, wherein the first portion consistsessentially of nitride-bonded silicon carbide, oxynitride-bonded siliconcarbide, or silicon carbide.
 8. The refractory article of claim 1,wherein the first portion comprises an average thermal conductivity ofat least 10 W/mK and not greater than 200 W/mK.
 9. The refractoryarticle of claim 1, wherein the second portion comprises silica.
 10. Therefractory article of claim 1, wherein the second portion comprises analuminosilicate.
 11. The refractory article of claim 1, wherein thesecond portion comprises mullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).
 12. Therefractory article of claim 1, wherein the second portion consistsessentially of mullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).
 13. The refractoryarticle of claim 1, wherein the second portion consists essentially ofpolycrystalline oxide material.
 14. The refractory article of claim 1,wherein the second portion is essentially free of an amorphous phasematerial.
 15. The refractory article of claim 1, further comprising athird portion disposed between the first portion and the second portion,wherein the third portion comprises at least one of an oxide and acarbide.
 16. The refractory article of claim 15, wherein the thirdportion comprises an oxide and a carbide.
 17. The refractory article ofclaim 15, wherein the third portion comprises at least a phasecomprising a material selected from the group of silicon carbide (SiC),silicon nitride (Si₃N₄), silicon oxynitride (Si₂ON₂), silica (SiO₂),mullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂), alumina, (Al₂O₃), siliconaluminum oxynitride (SiAlON), or any combination thereof.
 18. Therefractory article of claim 15, wherein the third portion comprises afirst phase comprising nitride-bonded silicon carbide and a second phasecomprising mullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).
 19. The refractoryarticle of claim 15, wherein the third portion comprises a first phasecomprising oxynitride-bonded silicon carbide and a second phasecomprising mullite (3Al₂O₃-2SiO₂ or 2Al₂O₃—SiO₂).
 20. The refractoryarticle of claim 15, wherein the third portion comprises a first phasecomprising silicon carbide (SiC) and a second phase comprising alumina(Al₂O₃).